US10181599B2 - Microwave drying of lithium-ion battery materials - Google Patents

Microwave drying of lithium-ion battery materials Download PDF

Info

Publication number
US10181599B2
US10181599B2 US14/385,761 US201314385761A US10181599B2 US 10181599 B2 US10181599 B2 US 10181599B2 US 201314385761 A US201314385761 A US 201314385761A US 10181599 B2 US10181599 B2 US 10181599B2
Authority
US
United States
Prior art keywords
electrode material
lithium
electrode
frequency
microwave
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
US14/385,761
Other versions
US20150074988A1 (en
Inventor
Chad Allison
Iftikhar Ahmad
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
A123 Systems LLC
Original Assignee
A123 Systems LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by A123 Systems LLC filed Critical A123 Systems LLC
Priority to US14/385,761 priority Critical patent/US10181599B2/en
Publication of US20150074988A1 publication Critical patent/US20150074988A1/en
Assigned to A123 Systems, LLC reassignment A123 Systems, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALLISON, Chad
Application granted granted Critical
Publication of US10181599B2 publication Critical patent/US10181599B2/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1391—Processes of manufacture of electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B13/00—Machines and apparatus for drying fabrics, fibres, yarns, or other materials in long lengths, with progressive movement
    • F26B13/10—Arrangements for feeding, heating or supporting materials; Controlling movement, tension or position of materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B21/00—Arrangements or duct systems, e.g. in combination with pallet boxes, for supplying and controlling air or gases for drying solid materials or objects
    • F26B21/14—Arrangements or duct systems, e.g. in combination with pallet boxes, for supplying and controlling air or gases for drying solid materials or objects using gases or vapours other than air or steam, e.g. inert gases
    • F26B21/40—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B3/00—Drying solid materials or objects by processes involving the application of heat
    • F26B3/32—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action
    • F26B3/34—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action by using electrical effects
    • F26B3/347—Electromagnetic heating, e.g. induction heating or heating using microwave energy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/04—Construction or manufacture in general
    • H01M10/0404—Machines for assembling batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/052—Li-accumulators
    • H01M10/0525—Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
    • H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
    • H01M10/0566—Liquid materials
    • H01M10/0568—Liquid materials characterised by the solutes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/056—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes
    • H01M10/0564—Accumulators with non-aqueous electrolyte characterised by the materials used as electrolytes, e.g. mixed inorganic/organic electrolytes the electrolyte being constituted of organic materials only
    • H01M10/0566—Liquid materials
    • H01M10/0569—Liquid materials characterised by the solvents
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/05—Accumulators with non-aqueous electrolyte
    • H01M10/058—Construction or manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0404—Methods of deposition of the material by coating on electrode collectors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/04—Processes of manufacture in general
    • H01M4/0402—Methods of deposition of the material
    • H01M4/0419—Methods of deposition of the material involving spraying
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/131—Electrodes based on mixed oxides or hydroxides, or on mixtures of oxides or hydroxides, e.g. LiCoOx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/133—Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/13—Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/139—Processes of manufacture
    • H01M4/1393—Processes of manufacture of electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
    • H01M4/50—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese
    • H01M4/505—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of manganese of mixed oxides or hydroxides containing manganese for inserting or intercalating light metals, e.g. LiMn2O4 or LiMn2OxFy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/48—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides
    • H01M4/52—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron
    • H01M4/525—Selection of substances as active materials, active masses, active liquids of inorganic oxides or hydroxides of nickel, cobalt or iron of mixed oxides or hydroxides containing iron, cobalt or nickel for inserting or intercalating light metals, e.g. LiNiO2, LiCoO2 or LiCoOxFy
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/36—Selection of substances as active materials, active masses, active liquids
    • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
    • H01M4/583—Carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • H01M4/587—Carbonaceous material, e.g. graphite-intercalation compounds or CFx for inserting or intercalating light metals
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H01M4/661—Metal or alloys, e.g. alloy coatings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49108—Electric battery cell making
    • Y10T29/4911—Electric battery cell making including sealing

Definitions

  • This disclosure relates to the fabrication of lithium-ion batteries, and more particularly, to using microwave radiation to desiccate electrode materials for use in a lithium-ion battery.
  • Each cell of a lithium-ion battery includes a negative electrode and a positive electrode.
  • the negative electrode may consist of a lithium-ion intercalated, reduced-carbon material dispersed on a copper or nickel substrate.
  • the positive electrode may consist of a lithium metal oxide dispersed on an aluminum substrate.
  • the positive and negative electrodes may be arranged in layers, with an insulating separator placed between them to prevent short circuit. The resulting layered structure may be folded or wound into the desired cell configuration, connected to the external contacts of the cell, wetted with a non-aqueous electrolyte solution, and then sealed in a suitable enclosure.
  • the performance and longevity of a lithium-ion cell may depend on the degree to which moisture—viz., water—is excluded from the materials sealed in the cell enclosure. Accordingly, the positive and negative electrode layers may be heated under vacuum to desiccate the electrode materials prior to addition of the electrolyte solution.
  • vacuum treatment is costly and time-consuming, and is not easily applicable to continuous—e.g., roll-to-roll processing.
  • one embodiment of this disclosure provides a method for making a lithium-ion cell.
  • the method includes depositing an electrode material as a coating on a substrate of the lithium-ion cell, irradiating the deposited electrode material with microwave radiation of varying frequency, wetting the irradiated electrode material with a non-aqueous electrolyte solution, and sealing the wetted electrode material in an air-tight enclosure.
  • Another embodiment provides an apparatus for making a lithium-ion cell.
  • the apparatus includes an electrode-material deposition stage, a microwave desiccation stage, a wetting stage, and a sealing stage.
  • the deposition stage is configured to deposit an electrode material as a coating on a substrate of the lithium-ion cell.
  • the desiccation stage includes a microwave emitter configured to irradiate the deposited electrode material with microwave radiation of varying frequency.
  • the wetting stage is configured to wet the irradiated electrode material with a non-aqueous electrolyte solution.
  • the sealing stage is configured to seal the wetted electrode material in an air-tight enclosure.
  • FIGS. 1A and 1B show aspects of lithium-ion cell electrodes in cross section, in accordance with embodiments of this disclosure.
  • FIG. 2A shows positive and negative electrodes as arranged for use in a cylindrical lithium-ion cell, in accordance with an embodiment of this disclosure.
  • FIG. 2B shows aspects of a cylindrical lithium-ion cell in accordance with an embodiment of this disclosure.
  • FIG. 3A shows positive and negative electrodes as arranged for use in a flat-pack lithium-ion cell, in accordance with an embodiment of this disclosure.
  • FIG. 3B shows a flat-pack lithium-ion cell in accordance with an embodiment of this disclosure.
  • FIG. 4 is a block diagram that represents an apparatus for making a lithium-ion cell in accordance with an embodiment of this disclosure.
  • FIG. 5 shows aspects of a microwave desiccation stage of an apparatus for making a lithium-ion cell in accordance with an embodiment of this disclosure.
  • FIG. 6 illustrates an example method for making a lithium-ion cell in accordance with an embodiment of this disclosure.
  • FIG. 7 illustrates an example method to irradiate electrode material in a microwave desiccation stage of an apparatus for making a lithium-ion cell, in accordance with an embodiment of this disclosure.
  • FIG. 1A schematically shows a lithium-ion cell electrode 10 in cross section.
  • the electrode includes a substrate 12 and an electroactive coating 14 supported on the substrate.
  • electrode 10 may be the positive electrode 10 P or the negative electrode 10 N of the cell.
  • the electroactive coating of the positive electrode may comprise a lithium metal oxide such as lithium cobaltate, lithium manganate, lithium nickelate, or lithium nickel cobaltate, to name only a few.
  • the substrate of the positive electrode may be aluminum foil.
  • the electroactive coating of the negative electrode may comprise any form of lithium-intercalated carbon, including lithium-intercalated graphite.
  • the substrate of the negative electrode may be copper or nickel foil.
  • either or both of the electroactive coatings may be applied from an aqueous or non-aqueous slurry to the corresponding substrate, thereby imparting a significant quantity of water to the electrodes.
  • either or both of the electrodes may include other materials as well, such as binders or adhesives, which may also contain water and/or other protic compounds.
  • FIG. 1A shows an electrode coated on only one side of the substrate
  • electrodes coated on both sides are fully consistent with this disclosure and fully applicable to the methods set forth hereinafter.
  • FIG. 1B shows an electrode 10 ′ having a substrate 12 coated on both sides with electroactive coatings 14 and 14 ′.
  • the coating on one side may be the same or at least somewhat different than the coating on the other side.
  • positive electrode 10 P and negative electrode 10 N may be rolled up into a ‘jellyroll’ structure 16 for use in a cylindrical lithium-ion cell.
  • the electrodes are layered and wound with a porous separator sheet 18 arranged between them, to prevent short circuit.
  • FIG. 2B shows an example cylindrical lithium-ion cell 19 with electrical contacts 20 , an enclosure 22 , and a sealing cap 23 .
  • the electrical contacts may be extensions of the substrates 12 P and 12 N of the positive and negative electrodes, respectively.
  • the positive and negative electrodes 10 P and 10 N, respectively may be layered and folded into a ‘flat-pack’ structure 24 , as in FIG. 3A , with a porous separator sheet 18 between them.
  • the latter configuration may be used in a flat-pack lithium-ion cell 25 , as shown in FIG. 3B .
  • a non-aqueous electrolyte solution e.g., a lithium salt dissolved in a polar aprotic solvent
  • the aprotic solvent may include one or more of ethylene carbonate, dimethylcarbonate, and diethylcarbonate.
  • the lithium salt may be a hygroscopic solid such as lithium hexafluorophosphate, lithium tetrafluoroborate, or lithium perchlorate.
  • FIG. 4 is a high-level block diagram showing various stages of an apparatus 26 for making a lithium-ion cell, in one embodiment.
  • the apparatus includes an electrode-material deposition stage 28 , a microwave desiccation stage 30 , a wetting stage 32 , and a sealing stage 34 .
  • the deposition stage is configured to deposit an electrode material as a coating on a substrate 12 of the lithium-ion cell.
  • the microwave desiccation stage is configured to irradiate the deposited electrode material with microwave radiation of varying frequency.
  • the microwave desiccation stage is configured to convey the electrode material and substrate as a continuous sheet.
  • the wetting stage is configured to wet the irradiated electrode material with a non-aqueous electrolyte solution.
  • the sealing stage is configured to seal the wetted electrode material in an air-tight enclosure.
  • FIG. 5 shows aspects of an example microwave desiccation stage 30 in one embodiment.
  • the illustrated microwave desiccation stage is configured to desiccate a continuous sheet of electrode material using variable-frequency microwave heating.
  • Microwave desiccation stage 30 includes feed roller 36 , from which the material to be desiccated is fed in.
  • the electrode is fed into the microwave dessication stage as a continuous sheet.
  • the feed roller may be configured to maintain a suitable amount of tension in the sheet.
  • the width of the sheet may be substantially the same as the width of an electrode in a finished lithium-ion cell.
  • the electrode material fed into the microwave desiccation stage may have the structure of positive electrode 10 P or negative electrode 10 N of the foregoing drawings; it may include an electroactive coating 14 arranged on a substrate 12 .
  • the electrode material fed into the microwave desiccation stage may have a more complex, layered structure. For example, it may include both positive and negative electrode layers, and one or more separator sheets 18 .
  • microwave desiccation stage 30 also includes gas conduit 38 , which has an inlet 40 , an outlet 42 , and an opening 44 of appropriate dimensions to allow the electrode material to pass through.
  • the gas conduit is configured to conduct a gas over the electrode material as the electrode material is being irradiated.
  • At least an upper window 46 of the gas conduit may be made of a microwave-transmissive material, such as glass or ceramic.
  • any dry, non-microwave absorbing gas may be admitted through inlet 40 and used to convey the humidity out of the gas conduit. Examples include nitrogen, argon, carbon dioxide, and de-humidified air.
  • Microwave desiccation stage 30 also includes uptake roll 48 , which is configured to draw the electrode material though the stage and to store the desiccated material for future use.
  • microwave desiccation stage 30 the primary mode of desiccation of the electrode material is heating by absorption of microwave radiation.
  • the apparatus includes microwave emitter 50 , which is configured to direct its emission through gas conduit 38 and onto the material to be desiccated.
  • fixed-frequency microwave irradiation may be disadvantageous for desiccating the electrode materials described herein. Without being bound by any particular theory, it is believed that fixed-frequency microwave irradiation causes nodal planes to build up in the irradiated space, which is problematic when the material to be desiccated includes a metal—e.g., the metal foil substrates 12 . Nodal planes are believed to induce currents and charge localizations in and mostly on conductive objects. This can lead to non-uniform heating, arcing, and damage to the electrodes. However, by scanning the frequency—i.e., changing the frequency of the radiation over time—these nodal planes can be averted, allowing the electrode material to heat up more uniformly.
  • microwave emitter 50 may be a variable-frequency microwave emitter.
  • the frequency of the radiation available from the microwave emitter may be adjustable continuously from 1.0 gigahertz (GHz) to 8.0 GHz.
  • the frequency of the radiation may be adjustable over the same range in discrete steps.
  • the frequency of the microwave emitter may be configured to ramp up or down as the electrode material is conveyed through the desiccation stage.
  • the varying frequency of the microwave radiation may be chosen to prevent nodal planes from forming along the electrode material. This feature may prevent undesirable effects especially when the substrate is a metal substrate irradiated along with the electrode material.
  • the overall power output of the microwave emitter may be 10 kilowatts per square meter of irradiated electrode material. In other embodiments, the power may be greater. In single-electrode testing, a maximum power of 500 watts was used. It will be noted, however, that the numerical values and ranges set forth herein are examples only, and that other values and ranges are also contemplated.
  • FIG. 6 illustrates an example method 52 for making a lithium-ion cell in one embodiment.
  • an electroactive coating is deposited on a foil substrate to form the positive or negative electrode material of the cell, as described hereinabove.
  • the substrate may be in the form of a continuous sheet.
  • the electroactive coating may be applied via a continuous spray-coating or transfer-coating process.
  • the electroactive coating may be applied from an aqueous or non-aqueous slurry.
  • the deposited electrode material is irradiated with microwave radiation in a microwave desiccation stage, such as microwave desiccation stage 30 .
  • the electrode material may be pre-dried or partially dried in air prior to entering the microwave desiccation stage.
  • the desiccated electrode material is layered with a complementary electrode material, which may also be desiccated by the same or a similar process.
  • the electrode materials may be layered together along with one or more separator layers, as described hereinabove.
  • the electrode material subject to microwave desiccation may include both positive and negative electrode materials deposited on their respective substrates, with a separator layer arranged between the positive and negative electrode materials.
  • the layered structure is folded or wound according to the desired final form of the lithium-ion cell.
  • electrical connection is made to the electrode substrate materials via external contacts of the cell, and the layered structure is inserted into an enclosure.
  • a non-aqueous electrolyte solution is added to the enclosure so that it wets the irradiated electrode material.
  • the enclosure is sealed, making it airtight.
  • FIG. 7 illustrates an example method 56 A to irradiate electrode material in a microwave desiccation stage of an apparatus for making a lithium-ion cell.
  • Method 56 A may be a more particular embodiment of block 56 of the foregoing method. However, method 56 A may also be used independently.
  • the electrode material is conveyed into a gas conduit.
  • the electrode material may be conveyed from a feed roller to an uptake roller, through an opening of the gas conduit.
  • a dry gas such as nitrogen, argon, carbon dioxide, or de-humidified air is flowed through the gas conduit from an inlet to an outlet. In other embodiments, forced gas flow may be omitted, as discussed hereinabove.
  • the frequency of the microwave emitter is set to an initial frequency, which may be 1.0 GHz in some examples.
  • the frequency of the microwave emitter is increased linearly to a final frequency.
  • the final frequency may be 8.0 GHz, and the ramping may take place over a period of 10 minutes.
  • the time period of the ramping may coincide with the time taken for a given portion of the electrode material to pass through the gas conduit or field of microwave irradiation from one end to the other.
  • the frequency may be ramped from the initial frequency to the final frequency and then back to the initial frequency in the time taken for one portion of the electrode material to pass from one end to the other.
  • this disclosure is also consonant with batch-type processing.
  • individual, stamped electrodes may be irradiated with variable-frequency microwaves under flowing gas to effect desiccation.
  • this technique also bakes out other volatile components—e.g., residues of protic compounds besides water that may be introduced via the binders and/or adhesives used in cell fabrication.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Microbiology (AREA)
  • General Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Biotechnology (AREA)
  • Health & Medical Sciences (AREA)
  • Molecular Biology (AREA)
  • Biomedical Technology (AREA)
  • Electromagnetism (AREA)
  • Textile Engineering (AREA)
  • Battery Electrode And Active Subsutance (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Secondary Cells (AREA)
  • Drying Of Solid Materials (AREA)

Abstract

A method for making a lithium-ion cell includes depositing an electrode material as a coating on a substrate of the lithium-ion cell, irradiating the deposited electrode material with microwave radiation of varying frequency, wetting the irradiated electrode material with a non-aqueous electrolyte solution, and sealing the wetted electrode material in an air-tight enclosure.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
This application is the United States National Phase of International Patent Application Serial No. PCT/US2013/031320, entitled “Microwave Drying of Lithium-Ion Battery Materials,” filed Mar. 14, 2013, which claims priority to U.S. Provisional Patent Application No. 61/611,716, entitled “Microwave Drying of Lithium-Ion Battery Materials,” filed Mar. 16, 2012, the entire contents of each of which are hereby incorporated by reference in their entirety for all purposes.
TECHNICAL FIELD
This disclosure relates to the fabrication of lithium-ion batteries, and more particularly, to using microwave radiation to desiccate electrode materials for use in a lithium-ion battery.
BACKGROUND AND SUMMARY
Each cell of a lithium-ion battery includes a negative electrode and a positive electrode. The negative electrode may consist of a lithium-ion intercalated, reduced-carbon material dispersed on a copper or nickel substrate. The positive electrode may consist of a lithium metal oxide dispersed on an aluminum substrate. The positive and negative electrodes may be arranged in layers, with an insulating separator placed between them to prevent short circuit. The resulting layered structure may be folded or wound into the desired cell configuration, connected to the external contacts of the cell, wetted with a non-aqueous electrolyte solution, and then sealed in a suitable enclosure.
Generally speaking, the performance and longevity of a lithium-ion cell may depend on the degree to which moisture—viz., water—is excluded from the materials sealed in the cell enclosure. Accordingly, the positive and negative electrode layers may be heated under vacuum to desiccate the electrode materials prior to addition of the electrolyte solution. However, vacuum treatment is costly and time-consuming, and is not easily applicable to continuous—e.g., roll-to-roll processing.
Accordingly, one embodiment of this disclosure provides a method for making a lithium-ion cell. The method includes depositing an electrode material as a coating on a substrate of the lithium-ion cell, irradiating the deposited electrode material with microwave radiation of varying frequency, wetting the irradiated electrode material with a non-aqueous electrolyte solution, and sealing the wetted electrode material in an air-tight enclosure. Another embodiment provides an apparatus for making a lithium-ion cell. The apparatus includes an electrode-material deposition stage, a microwave desiccation stage, a wetting stage, and a sealing stage. The deposition stage is configured to deposit an electrode material as a coating on a substrate of the lithium-ion cell. The desiccation stage includes a microwave emitter configured to irradiate the deposited electrode material with microwave radiation of varying frequency. The wetting stage is configured to wet the irradiated electrode material with a non-aqueous electrolyte solution. The sealing stage is configured to seal the wetted electrode material in an air-tight enclosure.
The statements above are provided to introduce a selected part of this disclosure in simplified form, not to identify key or essential features. The claimed subject matter, defined by the claims, is limited neither to the content above nor to implementations that address any problems or disadvantages referenced herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show aspects of lithium-ion cell electrodes in cross section, in accordance with embodiments of this disclosure.
FIG. 2A shows positive and negative electrodes as arranged for use in a cylindrical lithium-ion cell, in accordance with an embodiment of this disclosure.
FIG. 2B shows aspects of a cylindrical lithium-ion cell in accordance with an embodiment of this disclosure.
FIG. 3A shows positive and negative electrodes as arranged for use in a flat-pack lithium-ion cell, in accordance with an embodiment of this disclosure.
FIG. 3B shows a flat-pack lithium-ion cell in accordance with an embodiment of this disclosure.
FIG. 4 is a block diagram that represents an apparatus for making a lithium-ion cell in accordance with an embodiment of this disclosure.
FIG. 5 shows aspects of a microwave desiccation stage of an apparatus for making a lithium-ion cell in accordance with an embodiment of this disclosure.
FIG. 6 illustrates an example method for making a lithium-ion cell in accordance with an embodiment of this disclosure.
FIG. 7 illustrates an example method to irradiate electrode material in a microwave desiccation stage of an apparatus for making a lithium-ion cell, in accordance with an embodiment of this disclosure.
 DETAILED DESCRIPTION
Aspects of this disclosure will now be described by example and with reference to the illustrated embodiments listed above. Components, process steps, and other elements that may be substantially the same in one or more embodiments are identified coordinately and are described with minimal repetition. It will be noted, however, that elements identified coordinately may also differ to some degree. It will be further noted that the drawing figures included in this disclosure are schematic and generally not drawn to scale. Rather, the various drawing scales, aspect ratios, and numbers of components shown in the figures may be purposely distorted to make certain features or relationships easier to see.
FIG. 1A schematically shows a lithium-ion cell electrode 10 in cross section. The electrode includes a substrate 12 and an electroactive coating 14 supported on the substrate. In general, electrode 10 may be the positive electrode 10P or the negative electrode 10N of the cell. The electroactive coating of the positive electrode may comprise a lithium metal oxide such as lithium cobaltate, lithium manganate, lithium nickelate, or lithium nickel cobaltate, to name only a few. The substrate of the positive electrode may be aluminum foil. The electroactive coating of the negative electrode may comprise any form of lithium-intercalated carbon, including lithium-intercalated graphite. The substrate of the negative electrode may be copper or nickel foil. In some embodiments, either or both of the electroactive coatings may be applied from an aqueous or non-aqueous slurry to the corresponding substrate, thereby imparting a significant quantity of water to the electrodes. Further, either or both of the electrodes may include other materials as well, such as binders or adhesives, which may also contain water and/or other protic compounds.
Although FIG. 1A shows an electrode coated on only one side of the substrate, electrodes coated on both sides are fully consistent with this disclosure and fully applicable to the methods set forth hereinafter. Accordingly, FIG. 1B shows an electrode 10′ having a substrate 12 coated on both sides with electroactive coatings 14 and 14′. In such embodiments, the coating on one side may be the same or at least somewhat different than the coating on the other side.
As shown in FIG. 2A, positive electrode 10P and negative electrode 10N may be rolled up into a ‘jellyroll’ structure 16 for use in a cylindrical lithium-ion cell. In this embodiment, the electrodes are layered and wound with a porous separator sheet 18 arranged between them, to prevent short circuit. FIG. 2B shows an example cylindrical lithium-ion cell 19 with electrical contacts 20, an enclosure 22, and a sealing cap 23. The electrical contacts may be extensions of the substrates 12P and 12N of the positive and negative electrodes, respectively. In other embodiments, the positive and negative electrodes 10P and 10N, respectively, may be layered and folded into a ‘flat-pack’ structure 24, as in FIG. 3A, with a porous separator sheet 18 between them. The latter configuration may be used in a flat-pack lithium-ion cell 25, as shown in FIG. 3B.
To complete the lithium-ion cells, a non-aqueous electrolyte solution—e.g., a lithium salt dissolved in a polar aprotic solvent—is injected into the enclosure, which is then sealed. In some embodiments, the aprotic solvent may include one or more of ethylene carbonate, dimethylcarbonate, and diethylcarbonate. In these and other embodiments, the lithium salt may be a hygroscopic solid such as lithium hexafluorophosphate, lithium tetrafluoroborate, or lithium perchlorate.
FIG. 4 is a high-level block diagram showing various stages of an apparatus 26 for making a lithium-ion cell, in one embodiment. The apparatus includes an electrode-material deposition stage 28, a microwave desiccation stage 30, a wetting stage 32, and a sealing stage 34. The deposition stage is configured to deposit an electrode material as a coating on a substrate 12 of the lithium-ion cell. The microwave desiccation stage is configured to irradiate the deposited electrode material with microwave radiation of varying frequency. In some embodiments, the microwave desiccation stage is configured to convey the electrode material and substrate as a continuous sheet. The wetting stage is configured to wet the irradiated electrode material with a non-aqueous electrolyte solution. The sealing stage is configured to seal the wetted electrode material in an air-tight enclosure.
As noted above, the performance and longevity of a lithium-ion cell may depend on the degree to which moisture is excluded from the materials sealed in the cell enclosure. Accordingly, FIG. 5 shows aspects of an example microwave desiccation stage 30 in one embodiment. The illustrated microwave desiccation stage is configured to desiccate a continuous sheet of electrode material using variable-frequency microwave heating.
Microwave desiccation stage 30 includes feed roller 36, from which the material to be desiccated is fed in. In the illustrated embodiment, the electrode is fed into the microwave dessication stage as a continuous sheet. Accordingly, the feed roller may be configured to maintain a suitable amount of tension in the sheet. In one embodiment, the width of the sheet may be substantially the same as the width of an electrode in a finished lithium-ion cell. In some embodiments, the electrode material fed into the microwave desiccation stage may have the structure of positive electrode 10P or negative electrode 10N of the foregoing drawings; it may include an electroactive coating 14 arranged on a substrate 12. In other embodiments, the electrode material fed into the microwave desiccation stage may have a more complex, layered structure. For example, it may include both positive and negative electrode layers, and one or more separator sheets 18.
Continuing in FIG. 5, microwave desiccation stage 30 also includes gas conduit 38, which has an inlet 40, an outlet 42, and an opening 44 of appropriate dimensions to allow the electrode material to pass through. The gas conduit is configured to conduct a gas over the electrode material as the electrode material is being irradiated. At least an upper window 46 of the gas conduit may be made of a microwave-transmissive material, such as glass or ceramic. In principle, any dry, non-microwave absorbing gas may be admitted through inlet 40 and used to convey the humidity out of the gas conduit. Examples include nitrogen, argon, carbon dioxide, and de-humidified air.
Although a flow of gas may aid in the electrode drying process, it may not be necessary in all applications. Accordingly, gas conduit 38 may be omitted in some embodiments in favor of an open structure where the material to be desiccated is conveyed through an open space, and where the humidity is carried away by convection into the atmosphere. Microwave desiccation stage 30 also includes uptake roll 48, which is configured to draw the electrode material though the stage and to store the desiccated material for future use.
In microwave desiccation stage 30, the primary mode of desiccation of the electrode material is heating by absorption of microwave radiation. Accordingly, the apparatus includes microwave emitter 50, which is configured to direct its emission through gas conduit 38 and onto the material to be desiccated.
The inventor herein has discovered that fixed-frequency microwave irradiation may be disadvantageous for desiccating the electrode materials described herein. Without being bound by any particular theory, it is believed that fixed-frequency microwave irradiation causes nodal planes to build up in the irradiated space, which is problematic when the material to be desiccated includes a metal—e.g., the metal foil substrates 12. Nodal planes are believed to induce currents and charge localizations in and mostly on conductive objects. This can lead to non-uniform heating, arcing, and damage to the electrodes. However, by scanning the frequency—i.e., changing the frequency of the radiation over time—these nodal planes can be averted, allowing the electrode material to heat up more uniformly.
Accordingly, microwave emitter 50 may be a variable-frequency microwave emitter. In one embodiment, the frequency of the radiation available from the microwave emitter may be adjustable continuously from 1.0 gigahertz (GHz) to 8.0 GHz. In another embodiment, the frequency of the radiation may be adjustable over the same range in discrete steps. Thus, the frequency of the microwave emitter may be configured to ramp up or down as the electrode material is conveyed through the desiccation stage. In some embodiments, the varying frequency of the microwave radiation may be chosen to prevent nodal planes from forming along the electrode material. This feature may prevent undesirable effects especially when the substrate is a metal substrate irradiated along with the electrode material.
In one, non-limiting embodiment, the overall power output of the microwave emitter may be 10 kilowatts per square meter of irradiated electrode material. In other embodiments, the power may be greater. In single-electrode testing, a maximum power of 500 watts was used. It will be noted, however, that the numerical values and ranges set forth herein are examples only, and that other values and ranges are also contemplated.
The configurations described above enable various methods for making a lithium-ion cell. Accordingly, some such methods are now described, by way of example, with continued reference to the above configurations. It will be understood, however, that the methods here described, and others fully within the scope of this disclosure, may be enabled by other configurations as well. Further, some of the process steps described and/or illustrated herein may, in some embodiments, be omitted without departing from the scope of this disclosure. Likewise, the indicated sequence of the process steps may not always be required to achieve the intended results, but is provided for ease of illustration and description. One or more of the illustrated actions, functions, or operations may be performed repeatedly, depending on the particular strategy being used.
FIG. 6 illustrates an example method 52 for making a lithium-ion cell in one embodiment. At 54 of method 52, an electroactive coating is deposited on a foil substrate to form the positive or negative electrode material of the cell, as described hereinabove. The substrate may be in the form of a continuous sheet. In one embodiment, the electroactive coating may be applied via a continuous spray-coating or transfer-coating process. In one embodiment, the electroactive coating may be applied from an aqueous or non-aqueous slurry.
At 56 the deposited electrode material is irradiated with microwave radiation in a microwave desiccation stage, such as microwave desiccation stage 30. In some embodiments, the electrode material may be pre-dried or partially dried in air prior to entering the microwave desiccation stage. At 58, the desiccated electrode material is layered with a complementary electrode material, which may also be desiccated by the same or a similar process. In one embodiment, the electrode materials may be layered together along with one or more separator layers, as described hereinabove. In other embodiments, the electrode material subject to microwave desiccation may include both positive and negative electrode materials deposited on their respective substrates, with a separator layer arranged between the positive and negative electrode materials.
At 60 the layered structure is folded or wound according to the desired final form of the lithium-ion cell. At 62, electrical connection is made to the electrode substrate materials via external contacts of the cell, and the layered structure is inserted into an enclosure. At 64, a non-aqueous electrolyte solution is added to the enclosure so that it wets the irradiated electrode material. At 66 the enclosure is sealed, making it airtight.
FIG. 7 illustrates an example method 56A to irradiate electrode material in a microwave desiccation stage of an apparatus for making a lithium-ion cell. Method 56A may be a more particular embodiment of block 56 of the foregoing method. However, method 56A may also be used independently.
At 68 of method 56A, the electrode material is conveyed into a gas conduit. In one embodiment, the electrode material may be conveyed from a feed roller to an uptake roller, through an opening of the gas conduit. At 70 a dry gas such as nitrogen, argon, carbon dioxide, or de-humidified air is flowed through the gas conduit from an inlet to an outlet. In other embodiments, forced gas flow may be omitted, as discussed hereinabove. At 72 the frequency of the microwave emitter is set to an initial frequency, which may be 1.0 GHz in some examples. At 74 the frequency of the microwave emitter is increased linearly to a final frequency. In one non-limiting example, the final frequency may be 8.0 GHz, and the ramping may take place over a period of 10 minutes. In one embodiment, the time period of the ramping may coincide with the time taken for a given portion of the electrode material to pass through the gas conduit or field of microwave irradiation from one end to the other. In another embodiment, the frequency may be ramped from the initial frequency to the final frequency and then back to the initial frequency in the time taken for one portion of the electrode material to pass from one end to the other.
Despite the numerous advantages of continuous—e.g., roll-to-roll processing of electrode materials for use in lithium-ion cells, this disclosure is also consonant with batch-type processing. In one example, individual, stamped electrodes may be irradiated with variable-frequency microwaves under flowing gas to effect desiccation. Furthermore, although water has been identified as the primary agent to be removed by microwave irradiation, this technique also bakes out other volatile components—e.g., residues of protic compounds besides water that may be introduced via the binders and/or adhesives used in cell fabrication.
Finally, it will be understood that the articles, systems, and methods described hereinabove are embodiments of this disclosure—non-limiting examples for which numerous variations and extensions are contemplated as well. Accordingly, this disclosure includes all novel and non-obvious combinations and sub-combinations of the articles, systems, and methods disclosed herein, as well as any and all equivalents thereof.

Claims (17)

The invention claimed is:
1. A method for making a lithium-ion cell, the method comprising:
depositing electrode materials including a positive electrode material and a negative electrode material as coatings on respective substrates of the lithium-ion cell, the substrates in the form of a continuous sheet;
passing the deposited electrode materials through a microwave radiation field of varying frequency while flowing a gas over the deposited electrode materials to heat the electrode materials before winding or folding the electrode materials with one or more separator layers, wherein the frequency increases linearly from an initial frequency to a final frequency, the increasing coincident with a time taken for a given portion of the electrode material to pass through the field of microwave radiation;
wetting the irradiated electrode materials with a non-aqueous electrolyte solution; and
sealing the wetted electrode materials in an air-tight enclosure.
2. The method of claim 1 wherein the electrode materials include one or more of lithium cobaltate, lithium manganate, lithium nickelate, and lithium nickel cobaltate.
3. The method of claim 1 wherein the electrode materials include lithium-intercalated carbon.
4. The method of claim 1 wherein the one or more separator layers are arranged between the positive and negative electrode materials.
5. The method of claim 1 wherein the electrode materials are applied from an aqueous slurry.
6. The method of claim 1 wherein depositing the electrode materials includes spray coating and/or transfer coating the electrode materials onto the respective substrates.
7. The method of claim 1 wherein one or more of the respective substrates includes a metal foil.
8. The method of claim 1 wherein the non-aqueous electrolyte solution includes one or more of ethylene carbonate, dimethylcarbonate, and diethylcarbonate.
9. The method of claim 1 wherein the non-aqueous electrolyte solution includes a dissolved hygroscopic solid.
10. An apparatus for making a lithium-ion cell, the apparatus comprising:
an electrode-material deposition stage configured to deposit an electrode material as a coating on a substrate of the lithium-ion cell;
a desiccation stage including a microwave emitter, a feed roller feeding the deposited electrode material as a continuous sheet to the desiccation stage, and a gas conduit with an inlet and an outlet, wherein the deposited electrode material is continuously irradiated with microwave radiation of an output power while ramping a frequency from a first frequency to a final frequency while passing through the gas conduit, wherein a gas is conducted through the gas conduit from the inlet to the outlet, and the feed roller is configured to maintain a suitable amount of tension in the sheet;
a wetting stage configured to wet the irradiated electrode material with a non-aqueous electrolyte solution; and
a sealing stage configured to seal the wetted electrode material in an air-tight enclosure.
11. The apparatus of claim 10 wherein the desiccation stage is configured to convey the electrode material and substrate as a continuous sheet.
12. The apparatus of claim 10 wherein the gas conduit includes a glass or ceramic window permeable to microwave radiation.
13. The apparatus of claim 10 wherein the ramped frequency of the microwave emitter is adjustable between 1 and 8 gigahertz.
14. The apparatus of claim 10 wherein a power of the microwave emitter is ten kilowatts per square meter or greater.
15. The apparatus of claim 14 wherein the ramped frequency of the microwave emitter is configured to ramp up or down as the electrode material is conveyed through the desiccation stage while the power of the microwave emitter is ten kilowatts per square meter or greater.
16. A method for making a lithium-ion cell, the method comprising:
depositing an electrode material as a coating on a substrate of the lithium-ion cell, the substrate in the form of a continuous sheet;
passing the deposited electrode material through a field of microwave irradiation, wherein the deposited electrode material is continuously irradiated with microwave radiation linearly increased from an initial frequency to a final frequency, the initial frequency and the final frequency chosen for a threshold output power and further to prevent nodal planes from forming along the electrode material, wherein the increasing coincides with a time taken for a given portion of the electrode material to pass through the field of microwave irradiation, wherein a feed roller for feeding the deposited electrode material through the field of microwave irradiation is configured to maintain a suitable amount of tension in the sheet;
folding or winding the electrode material with one or more separator layers;
wetting the irradiated electrode material with a non-aqueous electrolyte solution; and
sealing the wetted electrode material in an air-tight enclosure.
17. The method of claim 16 wherein the substrate includes a metal, which is irradiated along with the electrode material.
US14/385,761 2012-03-16 2013-03-14 Microwave drying of lithium-ion battery materials Active US10181599B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US14/385,761 US10181599B2 (en) 2012-03-16 2013-03-14 Microwave drying of lithium-ion battery materials

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201261611716P 2012-03-16 2012-03-16
PCT/US2013/031320 WO2013138588A1 (en) 2012-03-16 2013-03-14 Microwave drying of lithium-ion battery materials
US14/385,761 US10181599B2 (en) 2012-03-16 2013-03-14 Microwave drying of lithium-ion battery materials

Publications (2)

Publication Number Publication Date
US20150074988A1 US20150074988A1 (en) 2015-03-19
US10181599B2 true US10181599B2 (en) 2019-01-15

Family

ID=49161808

Family Applications (1)

Application Number Title Priority Date Filing Date
US14/385,761 Active US10181599B2 (en) 2012-03-16 2013-03-14 Microwave drying of lithium-ion battery materials

Country Status (6)

Country Link
US (1) US10181599B2 (en)
JP (1) JP6266589B2 (en)
KR (1) KR102027616B1 (en)
CN (1) CN104521055A (en)
DE (1) DE112013001480T5 (en)
WO (1) WO2013138588A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11936028B1 (en) 2020-07-13 2024-03-19 Ampcera Inc. Systems and methods for heating electrochemical systems
US12057561B1 (en) 2019-07-12 2024-08-06 Ampcera Inc. Systems and methods for induction heating of electrolytes
US12272809B1 (en) 2019-11-16 2025-04-08 Ampcera Inc. Battery cell, battery module, battery pack, electric vehicle, and method of heating

Families Citing this family (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101839379B1 (en) * 2013-10-31 2018-03-16 주식회사 엘지화학 Method for preparing lithium transition metal oxide comprising a step of drying by microwave and lithium transition metal oxide prepared thereby
JP6327090B2 (en) * 2014-09-29 2018-05-23 株式会社豊田自動織機 Method for manufacturing electrode for power storage device
KR101865212B1 (en) 2016-01-22 2018-06-07 한국과학기술연구원 VN catalyst support for fuel cell, Pt/VN catalyst comprising the same and method of preparing the same
EP3465803B1 (en) 2016-06-07 2021-05-05 Navitas Systems LLC High loading electrodes
CN107388740A (en) * 2017-07-19 2017-11-24 河北工业大学 A kind of lithium battery pole slice rolls up vacuum bakeout drying production line
US20190132910A1 (en) * 2017-11-02 2019-05-02 Applied Materials, Inc. Tool architecture using variable frequency microwave for residual moisture removal of electrodes
WO2022033637A1 (en) * 2020-08-12 2022-02-17 Fricke Und Mallah Microwave Technology Gmbh Drying of filter modules and filter housings using a frequency-guided microwave process
CN112815684B (en) * 2021-02-02 2022-12-09 江西春兴新能源有限公司 Continuous microwave drying process method for solidified polar plate of storage battery
CN112871599A (en) * 2021-02-02 2021-06-01 江西春兴新能源有限公司 Microwave drying kiln for drying accumulator plate
DE102021210160A1 (en) 2021-09-14 2023-03-16 Volkswagen Aktiengesellschaft Process for manufacturing an electrode of a battery
DE102021125494A1 (en) * 2021-10-01 2023-04-06 Bayerische Motoren Werke Aktiengesellschaft Method for producing an electrode, an electrode and an energy storage cell
DE102022120125A1 (en) * 2022-08-10 2024-02-15 Bayerische Motoren Werke Aktiengesellschaft Method for transferring process parameters of a one- or two-chamber dryer for drying a coating applied to a substrate to a chamber dryer with at least three drying chambers
WO2025085302A1 (en) * 2023-10-20 2025-04-24 Applied Materials, Inc. Transfer tool configuration for safe transfer of lithium onto a substrate

Citations (34)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3528179A (en) * 1968-10-28 1970-09-15 Cryodry Corp Microwave fluidized bed dryer
US4718176A (en) * 1985-05-23 1988-01-12 MAGNETI MARELLI S.p.A. Method and plant for the manufacture of dry-charged storage batteries
US5462820A (en) 1993-11-02 1995-10-31 Fuji Photo Film Co., Ltd. Non-aqueous battery with a block copolymer sealing member
US5654114A (en) 1994-03-25 1997-08-05 Fuji Photo Film Co., Ltd. Nonaqueous secondary battery
US5792574A (en) 1996-03-04 1998-08-11 Sharp Kabushiki Kaisha Nonaqueous secondary battery
US5985488A (en) 1996-03-26 1999-11-16 Sharp Kabushiki Kaisha Process for preparing positive electrode active material, and nonaqueous secondary battery utilizing the same
US6152971A (en) 1996-11-06 2000-11-28 Dai Nippon Printing Co., Ltd. Electrode plate for secondary battery with nonaqueous electrolyte and process for producing same
US6162264A (en) 1996-06-17 2000-12-19 Dai Nippon Printing Co., Ltd. Process for producing porous coating layer electrode plate for secondary battery with nonaqueous electrolyte process for producing same and sheet for peeling active material layer
US6306215B1 (en) * 1998-03-10 2001-10-23 Valence Technology, Inc. Apparatus for coating current collectors
US20030087158A1 (en) * 2001-11-08 2003-05-08 Ngk Insulators, Ltd. Lithium secondary battery
US20050031961A1 (en) 2003-01-08 2005-02-10 Masayuki Tsunekawa Electrode plate for battery, nonaqueous electrolyte battery, and process for producing thereof
US20050130039A1 (en) 2003-09-30 2005-06-16 Toshihito Shimizu Electrode plate for nonaqueous electrolyte secondary battery, method of producing the same and nonaqueous electrolyte secondary battery
US6998191B2 (en) 2001-11-08 2006-02-14 Dai Nippon Printing Co, Ltd Coating composition for negative electrode, negative electrode plate, method for producing the same, and secondary battery with nonaqueous electrolyte
US20060141138A1 (en) 2004-12-29 2006-06-29 3M Innovative Properties Company Microwave annealing of membranes for use in fuel cell assemblies
US7081320B2 (en) 1992-11-30 2006-07-25 Canon Kabushiki Kaisha High energy density secondary battery for repeated use
US20070215612A1 (en) * 2006-03-20 2007-09-20 Hicks Keith R Apparatus and method for microwave processing of materials
US7303594B2 (en) 2001-12-27 2007-12-04 The Gillette Company Battery electrode and method of making the same
CN101090151A (en) 2007-08-14 2007-12-19 深圳市海盈科技有限公司 Manufacturing method of lithium ion battery plus-negative plate
JP2008103098A (en) 2006-10-17 2008-05-01 Matsushita Electric Ind Co Ltd Method for manufacturing electrode plate for non-aqueous electrolyte secondary battery and apparatus for manufacturing the same
US7378189B2 (en) 2003-05-30 2008-05-27 Canon Kabushiki Kaisha Electrode material for lithium secondary battery, electrode structure employing electrode material, and lithium secondary battery having electrode structure
US20080131782A1 (en) 2003-06-24 2008-06-05 Canon Kabushiki Kaisha Electrode material for lithium secondary battery, electrode structure and lithium secondary battery
US20080184918A1 (en) * 2005-04-28 2008-08-07 Soo Dong Kim Food Waste Treatment Apparatus Using Microwave
US20090110992A1 (en) 2007-10-30 2009-04-30 Bloom Energy Corporation SOFC electrode sintering by microwave heating
US20090211522A1 (en) * 2008-02-21 2009-08-27 Gm Global Technology Operations, Inc. Use of Variable Frequency Microwaves to Control the Teflon Profile of Gas Diffusion Media
JP2010108624A (en) 2008-10-28 2010-05-13 Furukawa Battery Co Ltd:The Manufacturing method of cathode plate for nonaqueous electrolyte secondary battery and nonaqueous electrolyte secondary battery
JP2010113874A (en) 2008-11-05 2010-05-20 Furukawa Battery Co Ltd:The Method for manufacturing positive electrode for lithium secondary battery, and lithium secondary battery
US20100206363A1 (en) 2009-02-17 2010-08-19 Samsung Electronics Co., Ltd Graphene sheet comprising an intercalation compound and process of preparing the same
US7851087B2 (en) 2000-11-17 2010-12-14 Toshiba Battery Co., Ltd. Enclosed nickel-zinc primary battery, its anode and production methods for them
US7854773B2 (en) 2003-09-30 2010-12-21 Dai Nippon Printing Co., Ltd. Method of producing an electrode plate for a nonaqueous electrolyte secondary battery
JP2011082059A (en) 2009-10-08 2011-04-21 Nissan Motor Co Ltd Electrode drying device and electrode drying method
US20110204548A1 (en) * 2010-02-25 2011-08-25 Jacob George Tray Assemblies And Methods For Manufacturing Ceramic Articles
JP2012022858A (en) 2010-07-14 2012-02-02 Tokyo Electric Power Co Inc:The Method for manufacturing electrode
JP2012033364A (en) 2010-07-30 2012-02-16 Furukawa Battery Co Ltd:The Method for manufacturing electrode of lithium ion secondary battery, and method for manufacturing lithium ion secondary battery
US20130266741A1 (en) * 2008-05-21 2013-10-10 Applied Materials, Inc. Microwave Rapid Thermal Processing of Electrochemical Devices

Patent Citations (38)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3528179A (en) * 1968-10-28 1970-09-15 Cryodry Corp Microwave fluidized bed dryer
US4718176A (en) * 1985-05-23 1988-01-12 MAGNETI MARELLI S.p.A. Method and plant for the manufacture of dry-charged storage batteries
US7081320B2 (en) 1992-11-30 2006-07-25 Canon Kabushiki Kaisha High energy density secondary battery for repeated use
US5462820A (en) 1993-11-02 1995-10-31 Fuji Photo Film Co., Ltd. Non-aqueous battery with a block copolymer sealing member
US5654114A (en) 1994-03-25 1997-08-05 Fuji Photo Film Co., Ltd. Nonaqueous secondary battery
US5792574A (en) 1996-03-04 1998-08-11 Sharp Kabushiki Kaisha Nonaqueous secondary battery
US5985488A (en) 1996-03-26 1999-11-16 Sharp Kabushiki Kaisha Process for preparing positive electrode active material, and nonaqueous secondary battery utilizing the same
US6162264A (en) 1996-06-17 2000-12-19 Dai Nippon Printing Co., Ltd. Process for producing porous coating layer electrode plate for secondary battery with nonaqueous electrolyte process for producing same and sheet for peeling active material layer
US6152971A (en) 1996-11-06 2000-11-28 Dai Nippon Printing Co., Ltd. Electrode plate for secondary battery with nonaqueous electrolyte and process for producing same
US6306215B1 (en) * 1998-03-10 2001-10-23 Valence Technology, Inc. Apparatus for coating current collectors
US7851087B2 (en) 2000-11-17 2010-12-14 Toshiba Battery Co., Ltd. Enclosed nickel-zinc primary battery, its anode and production methods for them
US20030087158A1 (en) * 2001-11-08 2003-05-08 Ngk Insulators, Ltd. Lithium secondary battery
JP2003208924A (en) 2001-11-08 2003-07-25 Ngk Insulators Ltd Lithium secondary battery
US6998191B2 (en) 2001-11-08 2006-02-14 Dai Nippon Printing Co, Ltd Coating composition for negative electrode, negative electrode plate, method for producing the same, and secondary battery with nonaqueous electrolyte
US7135253B2 (en) 2001-11-08 2006-11-14 Ngk Insulators, Ltd. High discharge current lithium secondary battery and method of manufacture
US7303594B2 (en) 2001-12-27 2007-12-04 The Gillette Company Battery electrode and method of making the same
US20050031961A1 (en) 2003-01-08 2005-02-10 Masayuki Tsunekawa Electrode plate for battery, nonaqueous electrolyte battery, and process for producing thereof
US7378189B2 (en) 2003-05-30 2008-05-27 Canon Kabushiki Kaisha Electrode material for lithium secondary battery, electrode structure employing electrode material, and lithium secondary battery having electrode structure
US7615313B2 (en) 2003-06-24 2009-11-10 Canon Kabushiki Kaisha Electrode material for lithium secondary battery including particles having central portion and surface portion, electrode structure and lithium secondary battery
US7640150B2 (en) 2003-06-24 2009-12-29 Canon Kabushiki Kaisha Method of judging the propriety of a positive electrode active material
US20080131782A1 (en) 2003-06-24 2008-06-05 Canon Kabushiki Kaisha Electrode material for lithium secondary battery, electrode structure and lithium secondary battery
US7854773B2 (en) 2003-09-30 2010-12-21 Dai Nippon Printing Co., Ltd. Method of producing an electrode plate for a nonaqueous electrolyte secondary battery
US20050130039A1 (en) 2003-09-30 2005-06-16 Toshihito Shimizu Electrode plate for nonaqueous electrolyte secondary battery, method of producing the same and nonaqueous electrolyte secondary battery
US20060141138A1 (en) 2004-12-29 2006-06-29 3M Innovative Properties Company Microwave annealing of membranes for use in fuel cell assemblies
US20080184918A1 (en) * 2005-04-28 2008-08-07 Soo Dong Kim Food Waste Treatment Apparatus Using Microwave
US20070215612A1 (en) * 2006-03-20 2007-09-20 Hicks Keith R Apparatus and method for microwave processing of materials
JP2008103098A (en) 2006-10-17 2008-05-01 Matsushita Electric Ind Co Ltd Method for manufacturing electrode plate for non-aqueous electrolyte secondary battery and apparatus for manufacturing the same
CN101090151A (en) 2007-08-14 2007-12-19 深圳市海盈科技有限公司 Manufacturing method of lithium ion battery plus-negative plate
US20090110992A1 (en) 2007-10-30 2009-04-30 Bloom Energy Corporation SOFC electrode sintering by microwave heating
US20090211522A1 (en) * 2008-02-21 2009-08-27 Gm Global Technology Operations, Inc. Use of Variable Frequency Microwaves to Control the Teflon Profile of Gas Diffusion Media
US20130266741A1 (en) * 2008-05-21 2013-10-10 Applied Materials, Inc. Microwave Rapid Thermal Processing of Electrochemical Devices
JP2010108624A (en) 2008-10-28 2010-05-13 Furukawa Battery Co Ltd:The Manufacturing method of cathode plate for nonaqueous electrolyte secondary battery and nonaqueous electrolyte secondary battery
JP2010113874A (en) 2008-11-05 2010-05-20 Furukawa Battery Co Ltd:The Method for manufacturing positive electrode for lithium secondary battery, and lithium secondary battery
US20100206363A1 (en) 2009-02-17 2010-08-19 Samsung Electronics Co., Ltd Graphene sheet comprising an intercalation compound and process of preparing the same
JP2011082059A (en) 2009-10-08 2011-04-21 Nissan Motor Co Ltd Electrode drying device and electrode drying method
US20110204548A1 (en) * 2010-02-25 2011-08-25 Jacob George Tray Assemblies And Methods For Manufacturing Ceramic Articles
JP2012022858A (en) 2010-07-14 2012-02-02 Tokyo Electric Power Co Inc:The Method for manufacturing electrode
JP2012033364A (en) 2010-07-30 2012-02-16 Furukawa Battery Co Ltd:The Method for manufacturing electrode of lithium ion secondary battery, and method for manufacturing lithium ion secondary battery

Non-Patent Citations (5)

* Cited by examiner, † Cited by third party
Title
Japan Patent Office, Office Action Issued in Application No. 2015-500609, dated Oct. 24, 2016, 9 pages.
Korean Intellectual Property Office, International Search Report of PCT/US2013/031320, dated Jun. 25, 2013, WIPO, 3 pages.
Machine translation JP2012-022858 (Year: 2012). *
State Intellectual Property Office of the People's Republic of China, Office Action and Search Report Issued in Application No. 201380025263.1, dated Apr. 6, 2016, 11 pages. (Submitted with Partial Translation).
State Intellectual Property Office of the People's Republic of China, Office Action Issued in Application No. 201380025263.1, dated Aug. 7, 2017, 6 pages. (Submitted with Partial Translation).

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12057561B1 (en) 2019-07-12 2024-08-06 Ampcera Inc. Systems and methods for induction heating of electrolytes
US12272809B1 (en) 2019-11-16 2025-04-08 Ampcera Inc. Battery cell, battery module, battery pack, electric vehicle, and method of heating
US11936028B1 (en) 2020-07-13 2024-03-19 Ampcera Inc. Systems and methods for heating electrochemical systems

Also Published As

Publication number Publication date
JP2015511056A (en) 2015-04-13
DE112013001480T5 (en) 2015-04-09
US20150074988A1 (en) 2015-03-19
KR102027616B1 (en) 2019-10-01
WO2013138588A1 (en) 2013-09-19
KR20150021019A (en) 2015-02-27
CN104521055A (en) 2015-04-15
JP6266589B2 (en) 2018-01-31

Similar Documents

Publication Publication Date Title
US10181599B2 (en) Microwave drying of lithium-ion battery materials
Nytén et al. Surface characterization and stability phenomena in Li 2 FeSiO 4 studied by PES/XPS
ES2909715T3 (en) Electrode Array Preparation Method
CN103474623B (en) The preparation method of cathode pole piece and electrochemical appliance
TWI511356B (en) Graphene electrode, energy storage device employing the same, and method for fabricating the same
CN103132116A (en) Flexible substrate processing apparatus
JP2017510042A (en) Active cathode materials for secondary lithium cells and batteries
KR101793040B1 (en) Manufacturing method of electrode active material for ultracapacitor, manufacturing method of ultracapacitor electrode using the electrode active material and ultracapacitorusing the electrode active material
KR20190061013A (en) Anode slurry for lithium ion battery
CN107658472A (en) Negative pole comprising mesh-type current-collector, include its lithium secondary battery and its manufacture method
JP2015511056A5 (en)
CN107871887A (en) Electrode assembly
JP2013157121A (en) System and method of assembling electrode assembly for secondary battery
WO2015141288A1 (en) Positive electrode for lithium ion secondary batteries, and lithium ion secondary battery
US10665852B2 (en) Method for reducing residual water content in battery material
Gao et al. A new finding on the enhancement of the ability of polysulfide adsorption of V2O5 by doping tungsten in lithium–sulfur batteries
CN109037565A (en) Composite diaphragm, preparation method and the lithium-sulfur cell comprising it
KR20130073482A (en) METHOD OF MANUFACTURING CATHODE ACTIVE MATERIAL FOR LITHIμm BATTERIES
JP5768883B2 (en) Lithium ion secondary battery and method for producing lithium ion secondary battery
Pervez et al. Crystalline iron oxide nanotube arrays with high aspect ratio as binder free anode for Li‐ion batteries
CN108028434A (en) Manufacturing method of electrochemical device and electrochemical device
JP2016081621A (en) Separator and lithium ion secondary battery using the same
JP2013201062A (en) Manufacturing method of all-solid lithium ion secondary battery
CN106684353A (en) Preparation method for carbon-coated potassium vanadium phosphate and application of carbon-coated potassium vanadium phosphate
JP7535232B2 (en) BATTERY ASSEMBLY AND METHOD FOR MANUFACTURING NON-AQUEOUS ELECTROLYTE SECONDARY BATTERY

Legal Events

Date Code Title Description
AS Assignment

Owner name: A123 SYSTEMS, LLC, MASSACHUSETTS

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:ALLISON, CHAD;REEL/FRAME:047685/0118

Effective date: 20150328

STCF Information on status: patent grant

Free format text: PATENTED CASE

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 4TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1551); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Year of fee payment: 4